Electrical connector



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ELECTRICAL CONNECTOR Saul P. Lippel, Oceanside, N.Y., assignor to EagleElectric Mfg. Co. Inc., Long Island City, N.Y., a corporation of NewYork Filed July 27, 1956, Ser. No. 600,502

3 Claims. (Cl. 339-196) This invention relates to an electricalconnector and more Particularly to an electrical connector for duplexelectrical conductor cords.

The prime object of the present invention centers about the productionof an improved electrical connector of the type disclosed in the LettersPatent to Sams and Feldman, No. 2,675,531, granted April 13, 1954.

This type of electrical connector comprises a body containing contactprongs, which form part of the contact terminals of the connector and towhich the wires of the duplex cord are to be connected, the said bodybeing formed internally with passages into and through which a duplexcord, the free end of which is merely cut or snipped with a scissors, ismoved in such a manner that the exposed wire ends of the duplex cord areforced into the prong contacts for making the necessary electricalcircuit connection. The connector thus comprises a unitary elementhaving no movable parts and no securing members (such as binding postsor screws) that require manipulation, attachment of a duplex or multiplewire cord to the connector being achieved merely by the act of insertingthe conductor cord into the connector, the wires or wire strand of theconnector being moved into electrical contact and engagement with theconnector prongs. There is thus provided a connector, the use of whicheliminates the necessity of stripping the wire, removing the insulationor fastening the wire by means such as connecting screws, posts or thelike, or of providing movable and manipulable elements for bringing thewires into contact engagement with prongs as are required in some of themore modern types of connectors.

It is the first purpose of the present invention to produce a connectorof the type referred to in which the connector body is made of twosections which are capable of being readily moldable and which may thenbe joined together and assembled with the contact terminals to form thedesired unitary structure, The first main object of the presentinvention, therefore, relates to the v devising of a construction whichserves to successfully achieve this purpose.

The main problem involved in the making of a connector of the referredto type is to so build the connector body and particularly the passagesthereof thru which the conductor cord is to move so that (1) theconductor cord may first be easily and unerringly guided thru thepassages towards the contact prongs and (2) the insulated wires of theduplex cord may be so moved thru the passage leading to the contactprongs that the ends of the wires may be maintained in proper and rigidalinement with the contact prongs for effecting the electrical circuitconnection. It is a further prime object of the invention to construct aconnector, particularly of the type in which the body comprises a pairof united sections, which effectively solves this main problem.

Another problem met with in the use of this connector is linked with thebehavior of a duplex cord when after Patented Nov. 8, 1960' beingattached to the connector is pulled to tighten the connection. Inpulling the cord after attachment, due to the difierence instretchability of the wires and the insulation, there is a movement(recession) of the Wires in the insulating jacket, interfering with theconnection of the wires to the contact prongs. It is, therefore, necessary to provide means for automatically constricting and thereby lockingthe cord in position at the inception of the pull exerted thereon. Theprovision of an effective constricting and locking means for thereferred to connector unit is another principal object of the presentinvention.

Other objects include so designing the unitary connector that the pairsof wires and contact prongs are so positioned as to be at all timesadequately insulated one pair from the other, and that the unit may becapable of being manufactured by quantity methods while maintaining thedesired degrees of tolerances.

To the accomplishment of the foregoing objects and such other objects asmay hereinafter appear my invention relates to the electrical connectoras sought to be defined in the appended claims taken together with thefollowing specification and the accompanying drawings in which:

Fig, 1 is a perspective view of the unitary electrical connector of thepresent invention;

Fig. 2 is a similar perspective view thereof showing the same with theduplex conductor wir inserted therein;

Fig. 3 is a top plan view of the connector drawn to an enlarged scale;

Fig. 4 is a side elevational view thereof;

Fig. 5 is a front elevational view thereof with one of the body sections(which may be referred to as the top section) removed therefrom;

Fig. 6 is an elevational view of the same showing the two sectionsnamely, the bottom section and the top section separated into an openposition (for purposes of illustration) i Fig. 7 is a view taken incross-section in the plane of the line 7, 7 of Fig. 5;

Fig. 8 is a view of the connector (with a duplex wire inserted) taken incross-section in the plane 3, 8 of Fig. 7;

Fig. 9 is a view of the connector taken in cross-section in the plane ofthe line 9, 9 of Fig. 5;

Fig. 10 is a view thereof taken in cross-section in the plane of theline 10, 10 of Fig. 7; and

Figs. 11 to 14A are sequential views (taken in vertical cross-sectionand in transverse cross-section) schematically depicting some of theprinciples of construction of the connector and the manner of using thesame.

Referring now more in detail to the drawings and having reference firstto Figs. 1 to 4 thereof which show the assembled connector unit andwhich partly shows the manner of using the same, the connector comprisesin its generalized aspect a body B made of two sections 20 and 22 joinedtogether, each section having channels mating with the other section,said channels defining a first passage P in said body extending inwardlyfrom jacket 30, said duplex cord being insertable first throughv thesecond passage P from the aperture 26, to the opening 24, and thencefrom said opening through the first passage P towards a plurality ofprongs contacts which form part of said conductor unit. The prongedcontacts comprise elements 30 and 32 which are formed integrally withthe electrical terminals or blades 34 and s 36 respectively of theconnector. The pronged contacts 30 and 32 extend into said first passageP in a direction opposite to the direction of insertion of the duplexcord C in said first passage P for making electrical circuit connectionwith the wires 28, one prong for each wire of said duplex cord C.

Referring now to Figs. 5 and .6 of the drawings, the body sections and22 are shown detailingly to comprise two half sections which are adaptedto be joined in a medial transverse plane (as shown in Figs. 1 to 4),each section 20 and 22 being formed with channels mating with channelsin the other section, said channels defining the passages P and P Thussections 2.0 and 22 are formed respectively with channels 38 and .40which are adapted to mate when the sections .are assembled to define orform the second passage P and these sections are also formedrespectively with the channels 42 and 44 which are adapted to mate whenthe sections are united to define or form the first passage P. The bodysections 20 and 22 each comprise a molded piece made of a suitableinsulation and formed with the walls and cavities to produce thereferred to channels and the other parts of the structure .to bedescribed later. The channels formed in the two sections merge with eachother at the opening 24 to form a return-bend loop generally designatedas 46. The channels 40 and 44 are otherwise separated by the wallformation 48 and the channels 38 and 42 by the wall formation 50.

For positioning and securely locking the electrical terminals includingtheir integral prongs in position suitable cavities and wall parts areformed in the molded sections as best shown in Figs. 5 and 6 of thedrawings. The electrical terminals desirably are shaped as shown inFigs. 5 and 6 in double-bent form. The receiving cavities for theseterminals (defined by suitable wall parts) are the cavity 52 in section20 which mates with the cavity 54 in section 22 and the cavity 56 insection 20 which mates with the cavity 58 in section 22. The prongedcontacts and 32 are located, one in one body section and the other inthe other body section (20 and 22); thus, the prong 30 is located in thebody section 20 and the prong 32 is located in the body section 22 (seee.g. Figs. 3 and 4). These prong contacts and their Wire engaging pointsare thus located both transversely and vertically of the connectorbodyB, and thus lie in a plane diagonally of the connector body B. The bodysections may also be formed with the spaced holes designated as 60 forreceiving rivets 62 to unite the sections in a unit (see Figs. 1 and 2).The mating sections may also be provided with additional locating meanscomprising a unitary pin 64 in section 20 which mates with a hole 66 insection 22.

The passages P and P and more particularly the chan nels which definethe same are designed as aforesaid so that the conductor cord may beeasily and unerringly guided through the passages towards the contactprongs and so that the insulated wires of the duplex cord may be movedthrough the passage P leading to the contact prongs with the ends of thewires rigidified as they approach the prongs and maintained in properand rigid alinement with the contact prongs for effecting the de siredelectrical circuit connection. The channels 38 and which form thepassage P are the same in contour and formation as best shown in Fig. 6.The channels 42 and 44 which define the first passage P are, however,different in contour and arrangement and for the purposes now to bedescribed. In Fig. 5 is shown the channel 44 of the bottom section 22;and here the channel 42 of the mating section 20 (removed) is shown inphantom lines. Fig. 5 therefore depicts these channels 42 and 44 asdiverging gradually in the direction from the opening 24 to the contactprongs 30 and 32. The channels 42 and 44 function to separately guideeach of the two inserted wire parts of the duplex cord, each insulatedwire being guided through one of,the channels. The guide means areespecially iformed as part of these channels for accomplishing the abovedescribed purposes; and this guide means comprises the opposed wallcorners 68 and 70 (see particularly Fig. 8) (see also Figs. 11 to 14) ofthe mating channels 42 and 44 respectively. These wall corners 68 and 70act as rails for engaging the medial region of the insulating jacket 30of the conductor cord .0 In most cases these insulating jackets,particularly when formed of an insulation made of rubber or of plasticare formed medially with grooves 72 (see particularly Fig. 8); and inthe movement of the cord into and through the passage P the wall cornerrails 68 and 70 engage these medial grooves for the guide function. Assoon as the channels 42 and 44 diverge in the direction towards thecontact prongs it will be observed that the said opposed corner rails 63and 70 gradually converge in the same direction. The results are that asthe duplex cord is moved into and through the passage P, the cord, firstmoving freely into the passage P in the region of the opening 24 is thenguided to move each of the insulated wires of the pair through itsseparate channel as clearly depicted in Fig. 8, the wall corner rails 68and 70 exerting a gradually increasing constriction on the mediallygrooved region of the cord with the ultimate result that the ends of thewires are moved and maintained in proper and rigid alinement with thecontact prongs for effecting the desired electrical circuit connection.This will be further explained in connection with the schematic views ofFigs. 11 to 14A of the drawings.

In Figs. 11 to 14A, which show sequentially, schematic views depictingthe movement of a duplex cord thru the passages P and P of theconnector, the parts corresponding to the parts of the connector shownin Figs. 1 to 10 are indicated by the same but primed referencecharacters. Elevational view Fig. 11 and top view Fig. 11A depict thecondition, indicated by the arrow, when the conductor cord C is about tobe passed into the aperture 26 of the passage P Elevational view Fig. 12and cross-sectional view Fig. 12A (taken in the plane of the line 12Ai2Aof Fig. 12) depict the condition when the cord C has been threadedthrough the passage P and after reaching the opening 24, has been loopedabout the return-bend loop 46' of the connector, for threading throughthe passage P. Elevational view Fig. 13 and sectional view Fig. 13A(taken in the plane of the line 13A-13A of Fig. 13) depict the conditionas the cord C is being threaded through the passage P. And elevationalview Fig. 14 and bottom view thereof Fig. 14A depict the condition whenthe cord C has been completely passed through the passage P and theoutside or other end of the cord has. been pulled to seat the loop ofthe cord firmly on the returnbend loop 46.

From these views it will be seen that the cord passes freely from theorifice 26' through the passage P is then looped and passes freely fromthe opening 24 into the entrant end of the passage P. It will then beseen that as the cord is threaded through the passage P, each insulatedwire thereof is moved and guided into its own channel, and that as thechannels 42 and 44 diverge and the corner rails 68 and 70 converge, themedial region (the grooves) 72' are engaged closer and tighter by thecorner rails with the etfect of stiffening or rigidifying the free endsof the cord for accurate alinement and positive inpingement connectionwith the contact prongs. In this action the insulated wires are orientedso as to lie transversely and, more particularly, diagonally of theconnector sections. The constriction efiected at the grooves also tendsto give a slight separation to the wires. This also affords asubstantial insulating separation between the prongs and the cord wires.It will also be observed that the channels have a cross-sectionsubstantially larger than the cord segments lodged therein, thispermitting such separation and also permitting the use of differentsizes of cords fora given size of a connector.

The means for .locking the cord in its connected or attached position ismade to consist of elements which crimp and thereby constrict the cordas a pull is exerted on the outside end of the cord to seat the loop ofthe cord on the return-bend loop 46 (see Fig. 5; also Fig. 14). Theseelements comprise mutually facing camming walls formed at thereverse-bend loop 46. This, and the effect thereof, is best shown inFig. 8; the facing walls of the sections 20 and 22 at the loop, formedat the top with end beads 74 and '76, are formed below the beads withconverging wall faces 78 and 80 which act as camming means to constrictand grip the cord at the loop or bend. This means also serves as astrain-relief. It will also be noted that when the cord is lodged in itsfinal position, the loop of the cord is fully housed by the connector.

To disconnect the conductor cord C from the connector, the operationshown in Figs. 11 to 14 is reversed. Thus the outside end of the cord isfirst pushed (Fig. 14) to free the cord loop from the reverse-bend loop46 (Fig. 13), forcing the cord to loop to the outside of the connector(as in Fig. 12), after which the cord is grasped at its loop and pulled;the cord is thus freed from the passage P and may then be pulled free ofthe passage P The manner of making and using the connector of thepresent invention, the advantages thereof and the results achieved willbe fully apparent from the above detailed description thereof. It Willbe further apparent that many changes may be made therein withoutdeparting from the spirit of the invention defined by the followingclaims.

I claim:

1. An electrical connector comprising a body made of two sections joinedtogether in a plane transversely of said connector body, each sectionhaving a channel mating with a channel of the other section, said matingchannels together defining a passage extending inwardly from an openinglocated at one end of said body and adapted to have inserted thereintofrom said opening a duplex conductor cord comprising a pair of insulatedwires joined together in an insulating jacket, a plurality of spacedterminal prongs having wire engaging contact points located at theopposite end of said body and lying in a plane diagonally of said body,one prong for each wire of the duplex cord extending into said passageand pointing in a direction opposite to the direction of insertion ofsaid duplex cord, one of said prongs being located in one of said matingchannels and the other of said prongs being located in the other of saidmating channels, insertion and movement of said duplex cord into saidpassage resulting in forcing the wires of the duplex cord into saidcontact points for making electrical circuit connection, the walls ofeach said channel defining a wall corner rail, the said mating channelsgradually diverging in the direction from said opening to said prongs,and opposed corner rails of said channels gradually converging in saiddirection, the said corner rails thereby defining guide means in saidpassage for guiding the duplex cord as the latter is moved into saidpassage and guiding each insulated wire through one of the channels andorienting the duplex cord to a position to lie diagonally of theconnector body, said corner rails acting to engage the medial -region ofthe insulating jacket of said duplex cord.

said connector body, each section having channels mating with channelsin the other section, said channels defining a first passage in saidbody extending inwardly from an opening located at one end of said bodyand a second passage in said body extending inwardly from an aperturelocated in a side of said body, said passages merging with each other atsaid opening to form a return-bend loop, the said passages being adaptedto receive a duplex conductor cord comprising a pair of insulated wiresjoined together in an insulating jacket, said duplex cord beinginsertable first through said second passage from aperture to openingand then from said opening through the first passage, a plurality ofspaced terminal prongs having wire engaging contact points located at anend of said body opposite said opening and lying in a plane diagonallyof said body, said points extending into said first passage and pointingin a direction opposite to the direction of insertion of said duplexcord in said first passage for making electrical circuit connection withthe wires, one point for each wire of said duplex cord, one of saidprongs being located in one of the mating channels of said first passageand the other of said prongs being located in the other mating channelof said first passage, the walls of each said channel defining a wallcorner rail, the said mating channels gradually diverging in thedirection from said opening to said prongs, and opposed corner rails ofsaid channels gradually converging in said direction, the said cornerrails thereby defining guide means in said first passage for guiding theduplex cord as the latter is moved into said first passage and guidingeach insulated wire through one of the channels and orienting the duplexcord to a position to lie diagonally of the connector body, said cornerrails acting to engage the medial region of the insulating jacket ofsaid duplex cord.

3. The electrical connector of claim 2, in which the said sections areformed at the return-bend loop with mutually facing camming walls forconstricting the loop of the cord and thereby locking the same when thesame is forced into said return-bend loop.

References Cited in the file of this patent UNITED STATES PATENTS1,665,510 Spidel Apr. 10, 1928 2,609,415 Benander et al. Sept. 2, 19522,675,531 Sams et al. Apr. 13, 1954 2,709,246 Abbott May 24, 19552,713,669 Cahn July 19, 1955 2,719,957 Abbott Oct. 4, 1955 2,742,623Odegaard et al. Apr. 17, 1956 FOREIGN PATENTS 386,685 Great Britain Ian.23, 1933

